Adjustable shoe for a power tool

ABSTRACT

A band saw includes a first wheel and a second wheel for supporting a continuous band saw blade, a motor operable to drive at least one of the first and second wheels, a housing supporting the first wheel and the second wheel, a shoe for engaging a workpiece, the shoe including a first detent feature. The band saw also includes a second detent feature cooperating with the first detent feature to hold the shoe with respect to the housing. The shoe is moveable with respect to the housing between an engaged position and a non-engaged position. The shoe is moveable out of the engaged position by application of a force acting to move the shoe with respect to the housing sufficient to overcome cooperation between the first and second detent features in the engaged position.

RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent application Ser. No. 12/508,824 filed on Jul. 24, 2009 which claims priority to U.S. Provisional Patent Application Ser. No. 61/083,703 filed on Jul. 25, 2008, and this application is also a continuation of co-pending U.S. patent application Ser. No. 12/794,023 filed on Jun. 4, 2010 which is a continuation-in-part of U.S. patent application Ser. No. 12/508,824 filed on Jul. 24, 2009 which claims priority to U.S. Provisional Patent Application Ser. No. 61/083,703 filed on Jul. 25, 2008, the entire contents of all of which are incorporated herein by reference.

BACKGROUND

The present invention relates to workpiece locators for power tools, and more particularly for band saws.

A band saw typically includes a drive wheel pulley, a motor coupled to the drive wheel pulley to drive the drive wheel pulley, a driven wheel pulley, and a continuous band saw blade looped around the drive wheel and the driven wheel. Band saws may also include a shoe to locate a workpiece with respect to a cutting portion of the band saw blade. The workpiece may be large or small and take on many various shapes. To remove the shoe or adjust a position of the shoe depending on the workpiece or type of cut to be made, a user uses a tool to release the shoe from a first position and secure it in a second position.

SUMMARY

In one aspect, the invention provides a band saw. The band saw includes a first wheel and a second wheel for supporting a continuous band saw blade, a motor operable to drive at least one of the first and second wheels, and a housing supporting the first wheel and the second wheel. The band saw also includes a shoe for engaging a workpiece, the shoe including a first detent feature. The band saw also includes a second detent feature cooperating with the first detent feature to hold the shoe with respect to the housing. The shoe is moveable with respect to the housing between an engaged position in which the first and second detent features cooperate to hold the shoe with respect to the housing, and a non-engaged position in which the first and second detent features do not cooperate. The shoe is moveable out of the engaged position by application of a force acting to move the shoe with respect to the housing sufficient to overcome cooperation between the first and second detent features in the engaged position.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side perspective view of a band saw including an adjustable shoe system according to one embodiment of the invention.

FIG. 2A is a bottom perspective view of the band saw of FIG. 1.

FIG. 2B is a top perspective view of a portion of the band saw shown in FIG. 1.

FIG. 3 is an exploded perspective view of the adjustable shoe system of FIG. 1.

FIG. 4 is a perspective view of the adjustable shoe system of FIG. 1.

FIG. 5A is a cross section of the adjustable shoe system taken along line 5A-5A of FIG. 4.

FIG. 5B is a cross section of a portion of the band saw taken along line 5B-5B of FIG. 2B.

FIG. 6 is a rear perspective view of the adjustable shoe system of FIG. 1.

FIG. 7 is a cross section of the adjustable shoe system taken along line 7-7 of FIG. 6.

FIG. 8 is a top perspective view of a band saw including a removable shoe system according to another embodiment of the invention.

FIG. 9 is a cross section of the removable shoe system taken along line 9-9 of FIG. 8.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION

FIGS. 1-7 illustrate a band saw 10 and an adjustable shoe system 91 embodying some aspects of the invention. An AC version of the band saw 10 having an electrical connection cord 12 is illustrated; however, in further embodiments, DC versions of the band saw 10 including a rechargeable, removable battery pack are possible.

The band saw 10 includes a housing or frame 14 supporting a motor 18 and a gear box 22. The motor 18 is drivingly connected to a drive mechanism (not shown) at least partially housed within the gear box 22. The motor 18 and the drive mechanism are operable to drive a continuous band saw blade 26 to cut a workpiece. As described herein, the band saw 10 includes a front 30 and a rear 34. The front 30 is defined as the side being proximate the portion of the band saw blade 26 that cuts the workpiece and the rear 34 is defined as the side proximate the portion of the band saw blade 26 that does not cut the workpiece. The rear 34 is otherwise described as being opposite the front 30.

The housing 14 includes a main handle 38 supporting a switch assembly 42 to provide power to the band saw 10. The switch assembly 42 is operable to control operation of the motor 18. The band saw 10 also includes an auxiliary handle 46 for a user's other hand spaced from the main handle 38. Generally, the handles 38, 46 are shaped and arranged for two-handed operation of the band saw 10 as the workpiece is cut. In the illustrated construction, each handle 38, 46 has an ergonomic design to provide comfortable gripping and controlled operation of the band saw. The ergonomic design of each handle and of the combination of the handles may include the orientation or angle of handle(s). The ergonomic design may also include the use of material, such as an elastomeric material, on the handle(s) to, one or more of, provide an improved grip surface, isolate vibration and impacts from the operator, prevent heat build-up and/or transfer to the operator, etc.

The housing 14 defines a first portion 50 and a second portion 54. The first portion 50 and the second portion 54 are spaced apart from one another and define a U-shaped cavity 66 defining a cut zone 58 therebetween. A blade guard 62 (FIG. 2A) is positioned at the rear 34 of the band saw 10 and extends between the first and second portions 50, 54 within the cut zone 58. The blade guard 62 provides a recessed area to house the band saw blade 26.

As shown in FIG. 2A, the drive mechanism generally includes a drive wheel pulley 70 and a driven wheel pulley 74. The drive wheel 70 rotates about a drive wheel axis 78 defined by a drive wheel axle 79 and is drivingly connected to the motor 18 via a drive train (not shown). The driven wheel 74 rotates about a driven wheel axis 82 defined by a driven wheel axle 83 and is rotatably supported by the housing 14. The drive wheel 70 is positioned in the first portion 50 of the housing 14, and the driven wheel 74 is positioned in the second portion 54 of the housing 14. A wheel tire 86 is coupled to each of the peripheries of the drive wheel 70 and the driven wheel 74. Each wheel tire 86 is a circular-shaped ring formed of a soft and/or flexible elastomeric material that is able to lock or adhere to the respective wheel 70, 74. The band saw blade 26 extends around the drive wheel 70 and the driven wheel 74 and grips the blade tires 86 and, as a result, motion from the drive wheel 70 is transmitted to the band saw blade 26 via the blade tires 86. The band saw 10 also includes a blade tensioning mechanism 90 to adjustably provide appropriate tension on the band saw blade 26.

A first guide roller set 110 and a second guide roller set 114 are disposed on each side of the cavity 66 and engage opposing sides of the saw blade 26. The first and second guide roller sets 110, 114 support the band saw blade 26 as the blade 26 enters and exits the cut zone 58.

The band saw 10 also includes an adjustable shoe system 91 including a shoe 92 for positioning against the workpiece, a connector block 96 for coupling the shoe 92 to the housing 14, and a detent mechanism 161 (FIGS. 5A and 5B) for holding the shoe 92 in select positions relative to the connector block 96. The shoe 92 is coupled to the housing 14 by way of the connector block 96 and the detent mechanism 161.

With reference to FIGS. 2A-7, the connector block 96 is a generally T-shaped member coupled to the housing 14 by fasteners 138. The connector block 96 is coupled to the first portion 50 of the housing 14 adjacent the drive wheel 70 and is positioned in or adjacent the cavity 66 at an end of the cut zone 58. The connector block 96 includes fastener apertures 142 through which the fasteners 138 are disposed to couple the connector block 96 to the housing 14. In the illustrated construction, two fastener apertures 142 (FIG. 5A) and two screws 138 (FIG. 5B) are employed. In other constructions, fewer or more fasteners and fastener apertures may be employed to couple the connector block 96 to the housing 14, or the connector block 96 may be integrally formed with the housing 14.

The connector block 96 includes a main body portion 146 and first and second extending portions or flanges 150, 154 generally forming a T-shape, as shown in FIG. 7. In the illustrated embodiment, the main body portion 146 is positioned adjacent the housing 14 and engages the housing 14 when the connector block 96 is fastened to the housing 14. The main body portion 146 includes first and second pins 170, 174 extending therefrom for locating the connector block 96 with respect to the housing 14. As illustrated in FIG. 5B, the pins 170, 174 are received by apertures or recesses in the housing 14. The first and second extending portions 150, 154 communicate with the shoe 92, as described below.

The connector block 96 also includes a recess or aperture 158 for receiving the detent mechanism 161 (FIGS. 5A and 5B). The detent mechanism 161 includes a ball detent 162 and a biasing member 166, such as a leaf spring. The ball detent 162 is biased by the biasing member 166 to an extended position away from the housing 14 for engaging the shoe 92 and holding the shoe 92 in position with respect to the housing 14. In other constructions, the biasing member 166 may include other types of springs and biasing members, such as a coil spring.

With further reference to FIGS. 3-7, the shoe 92 includes a generally C-shaped body member 172 and a workpiece-engaging member 176. The body member 172 wraps around and slideably engages the first and second extending portions 150, 154 of the connector block 96. An axis 98 of the adjustable shoe system 91 is defined by the direction the shoe 92 slides relative to the connector block 96. The axis 98 is also defined by an axis of symmetry of the body member 172. In the illustrated embodiment, the detent mechanism aperture 158 and the fastener apertures 184 are centered on the axis 98. The workpiece-engaging member 176 generally extends along the axis 98 below the cut zone 58 and away from the housing 14 of the band saw 10. The shoe 92, and in particular the workpiece-engaging member 176, engages a workpiece (not shown) in order to secure the workpiece relative to the band saw blade 26 within the cut zone 58 during a cutting operation. The workpiece-engaging member 176 includes a groove or slot 180 in which the band saw blade 26 is positioned, as shown in FIGS. 2A-2B. The direction of movement of the band saw blade 26 through the slot 180 is generally perpendicular to the axis 98, and a plane of the band saw blade 26 extending through the slot 180 is generally parallel to the axis 98.

Referring to FIGS. 2A-6, the shoe 92 includes apertures 184 for receiving the detent mechanism 161 and holding or locating the shoe 92 in position relative to the housing 14. The ball detent 162 is biased toward the shoe 92 and is received by one of the apertures 184 to engage the shoe 92 and hold the shoe 92 in a position corresponding to the respective aperture 184. In the construction of FIGS. 2A-7, the shoe 92 includes two apertures 184 and is adjustable between a first engaged position and a second engaged position. In the first position, the ball detent 162 is received by a first of the apertures 184 and engages the shoe 92 to hold the shoe 92 in the first position (FIGS. 2A, 2B, and 5A-6), i.e., to hold the shoe 92 with respect to the connector block 96. In the second position, the ball detent 162 is received by a second of the apertures 184 and engages the shoe 92 to hold the shoe 92 in the second position.

The first position is an extended position, extending away from the housing 14, for accommodating larger workpieces. The second position is a recessed position, recessed toward the housing 14, for accommodating smaller workpieces or cutting flush against a surface, such as a ceiling or wall. In the fully recessed position, the end of the shoe is adjacent or near a bottom edge (i.e., the cutting edge) of the band saw blade 26. A non-engaged position includes a position in between the first and second positions. In the non-engaged position, the ball detent 162 is not received by the apertures 184. The non-engaged position may also include a position in which the shoe 92 is removed from the connector block 96. In other constructions, three or more apertures 184 may be employed such that the shoe 92 is adjustable between three or more positions ranging from a fully extended to a fully recessed and intermediate positions therebetween for positioning and securing the band saw 10 with respect to a variety of workpieces of varying sizes and shapes.

FIGS. 8-9 illustrate a removable shoe system 178, given the same reference numerals as the adjustable shoe system 91 shown in FIGS. 1-7. The removable shoe system 178 is similar to the adjustable shoe system 91 except that the shoe 92 includes only one aperture 184. In this construction, the shoe 92 is moveable between an engaged position in which the ball detent 162 is received by the aperture 184 and a non-engaged position in which the shoe 92 is removed from the connector block 96. The non-engaged position may also include an intermediate position in which the shoe 92 is not removed, but in which the ball detent 162 does not engage the aperture 184.

In order to adjust the position of the shoe 92, a user applies a force on the shoe 92 in the direction of the axis 98. The force causes the body of the shoe 92 to engage the ball detent 162 and overcome the biasing force of the biasing member 166. The ball detent 162 is moved toward the housing 14 and engages an inner surface of the shoe 92 as the shoe 92 is moved to another position or removed. When one of the apertures 184 is positioned adjacent the ball detent 162, the ball detent 162 is pushed at least partially into the one of the apertures 184 by the biasing spring force and engages the body of the shoe 92 surrounding the one of the apertures 184 to hold the shoe 92 in place. In operation, the shoe 92 is adjusted by applying a force on the shoe 92 in either direction along the axis 98 to move the shoe 92 to a desired position depending on the size and shape of the workpiece being cut, or to remove the shoe 92. No tools or removal of fasteners are required to adjust or remove the shoe 92.

Although particular constructions embodying independent aspects of the present invention have been shown and described, other alternative constructions will become apparent to those skilled in the art and are within the intended scope of the independent aspects of the present invention. 

What is claimed is:
 1. A band saw comprising: a first wheel and a second wheel for supporting a continuous band saw blade; a motor operable to drive at least one of the first and second wheels; a housing supporting the first wheel and the second wheel; a shoe for engaging a workpiece, the shoe including a first detent feature; and a second detent feature cooperating with the first detent feature to hold the shoe with respect to the housing; wherein the shoe is moveable with respect to the housing between an engaged position in which the first and second detent features cooperate to hold the shoe with respect to the housing, and a non-engaged position in which the first and second detent features do not cooperate; wherein the shoe is moveable out of the engaged position by application of a force acting to move the shoe with respect to the housing sufficient to overcome cooperation between the first and second detent features in the engaged position.
 2. The band saw of claim 1, wherein the body is moveable out of the engaged position by application of a force directly on the shoe sufficient to overcome cooperation between the first and second detent features in the engaged position and cause the shoe to move relative to the housing.
 3. The band saw of claim 1, wherein the shoe is moveable out of the engaged position by application of a force on the shoe in a direction substantially parallel to a direction of movement of the shoe relative to the housing, the force being sufficient to overcome cooperation between the first and second detent features in the engaged position and cause the shoe to move relative to the housing.
 4. The band saw of claim 1, wherein first and second outwardly extending flanges extend from the housing, and wherein the shoe includes a generally C-shaped member for slideably engaging the first and second flanges.
 5. The band saw of claim 4, wherein the first and second outwardly extending flanges extend from a main portion such that the first and second outwardly extending flanges and the main portion have a generally T-shaped cross section shaped to be received by the generally C-shaped member.
 6. The band saw of claim 1, wherein the second detent feature includes a biasing member and a ball biased in a first direction by the biasing member, and the first detent feature includes a first aperture in the shoe for receiving the ball to hold the shoe with respect to the housing in the engaged position.
 7. The band saw of claim 6, wherein the engaged position is a first engaged position, and wherein the shoe further includes a second aperture for receiving the ball to hold the shoe with respect to the housing in a second engaged position.
 8. The band saw of claim 6, wherein the biasing member includes a leaf spring.
 9. The band saw of claim 6, wherein the biasing member biases the ball toward the shoe.
 10. The band saw of claim 1, wherein the non-engaged position includes a removed position in which the shoe is disengaged from the housing such that the shoe is removable.
 11. The band saw of claim 1, wherein the shoe is moveable between a plurality of engaged positions. 